The Duisburg Base of thyssenkrupp Steel Europe is truly vast. The plant covers nine square kilometres, has 440km of road networks and a working population of 28,000 people and it incorporates a smelting works with four furnaces for flat steel production. Every year it processes up to 12 million tons of iron ore into high-grade steel for a wide range of applications including automotive, civil engineering and household appliances.
Secure supply of compressed air is critical to plant safety
The plant’s liquid or gaseous media and the secure supply of compressed air are critical factors in its smooth operation within a network that incorporates 100km of compressed air piping supplying power to pneumatic consumers across the whole site.
New regulations meant that three large refrigeration dryers for the plant's compressed air network had to be replaced (each with a flow rate of 28,000 Nm3/h).
Six new specially developed refrigeration dryers with an airflow quantity of 14,000 Nm3/h per unit were built and installed. Doubling the number of units not only safeguards plant operations in the event of a fault, but also enables repair work to be performed on the cooling circuit by thyssenkrupp Steel Europe’s own staff without downtime.
Dryers of this type and size are rare and the units supplied by us, included numerous new and unique efficiency-enhancing measures that are serving as a model for the power optimisation and maintenance efficiency of compressed air dryers.
How a successful partnership leads to pioneering a standard
The work here is a great example of a successful partnership leading to a pioneering standard in terms of energy efficiency while reducing costs. The control systems for the dryers have been jointly designed and all dryer performance data is continually monitored and recorded. A switch cabinet with a touch panel is installed next to each individual dryer to monitor and read relevant operation data and conditions, and a central touch panel shows the data of all the dryers. Error messages and performance diagrams illustrate the continuous state of operations. In the event of a fault, an affected dryer automatically switches itself off and another goes on to the grid so that maximum plant availability is guaranteed.
Because thyssenkrupp Steel Europe places great importance on energy efficiency and conserving resources, Parker included a pump for the cool water circulation to keep condensation temperatures constant all year round, while saving water and preventing oil loss in the winter.
“This was a special project for both thyssenkrupp Steel Europe and Parker Hiross Zander, not only because the dryers’ exceptional efficiency broke new technological ground, but also because of the extensive know-how and clear goal-setting of the project managers who made this an exemplary team project.”
Frank Mehler, Senior Engineer District Cooling, thyssenkrupp Steel Europe, Germany
This installation represents a pioneering standard in terms of energy efficiency, maintenance engineering and optimized performance for the large dryer sector.
Article contributed by Christiaan P. Klaus, Marketing Communications & Services Manager Gas Filtration & Separation Platform EMEA
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